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KOMATSU PC360LC-10 PC390LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – Pdf download
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- KOMATSU PC360LC-10 PC390LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM025204
- SERIAL NUMBERS: PC360LC-10 A32001 and up
PC360LC-10 K64001 and up
PC390LC-10 A30001 and up
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Description
KOMATSU PC360LC-10 PC390LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
KOMATSU PC360LC-10 PC390LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU PC360LC-10 PC390LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- 01 GENERAL: This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
- 10 STRUCTURE AND FUNCTION: This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
- 20 STANDARD VALUE TABLE: This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
- 30 TESTING AND ADJUSTING: This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
- 40 TROUBLESHOOTING: Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
- 50 DISASSEMBLY AND ASSEMBLY: This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
- 60 MAINTENANCE STANDARD: This section gives the judgement standards when inspecting disassembled parts.
- 80 AIR CONDITIONING : This section explains the air conditioning system, structure and function, troubleshooting, disassembly, and assembly.
- 90 DIAGRAMS AND DRAWINGS : This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
KOMATSU PC360LC-10 PC390LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
PC360-390LC-10 Shop Manual CEBM025204..................................................................................................... 1 00 FORWARD................................................................................................................................ 0 CONTENTS.............................................................................................................................. 2 SAFETY................................................................................................................................ 19 Safety Notice..................................................................................................................... 19 Important Safety Notice....................................................................................................... 19 General Precautions........................................................................................................... 19 Preparations For Work......................................................................................................... 21 Precautions During Work....................................................................................................... 21 GENERAL............................................................................................................................... 24 HOW TO READ THE SHOP MANUAL........................................................................................................... 26 Volumes........................................................................................................................... 26 Distribution And Updating......................................................................................................... 26 Filing Method..................................................................................................................... 26 Revised Edition Mark.............................................................................................................. 26 Revisions......................................................................................................................... 26 Symbols........................................................................................................................... 26 HOISTING INSTRUCTIONS................................................................................................................. 27 Hoisting.......................................................................................................................... 27 Making Signs...................................................................................................................... 27 Precautions....................................................................................................................... 27 Precautions for Sling Work.................................................................................................... 27 Precautions for Using Mobile Crane............................................................................................ 28 Precautions for Using Overhead Hoist Crane.................................................................................... 28 Selecting Wire Ropes.............................................................................................................. 30 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.................................................................................. 31 Points to Remember When Handling Electric Equipment............................................................................... 31 Points to Remember When Handling Hydraulic Equipment.............................................................................. 42 PUSH PULL COUPLER..................................................................................................................... 44 Type 1............................................................................................................................ 44 Disconnection................................................................................................................. 44 Connection.................................................................................................................... 44 Type 2............................................................................................................................ 45 Disconnection................................................................................................................. 45 Connection.................................................................................................................... 45 Type 3............................................................................................................................ 46 Disconnection................................................................................................................. 46 Connection.................................................................................................................... 46 EXPLANATION OF MAINTENANCE STANDARD TERMS............................................................................................. 47 HANDLING OF FUEL SYSTEM DEVICES....................................................................................................... 48 HANDLING OF INTAKE SYSTEM PARTS....................................................................................................... 49 STANDARD TIGHTENING TORQUE............................................................................................................ 50 Bolts And Nuts.................................................................................................................... 50 Tightening Torque Of Hose Nuts.................................................................................................... 51 Tightening Torque Of Split Flange Bolts........................................................................................... 51 Tightening Torque For Flared Nuts................................................................................................. 51 Tightening Torques for Split Flanged Bolts........................................................................................ 52 Tightening Torques For O-ring Boss Piping Joints.................................................................................. 52 Table Of Tightening Torques For O-ring Boss Plugs................................................................................. 52 Tightening Torque For Hoses (Taper Seal Type And Face Seal Type).................................................................. 53 Tightening Torque For Face Seal Joints........................................................................................ 53 For 102, 107, and 114 Engine Series (Bolts and Nuts).......................................................................... 53 For 102, 107, and 114 Engine Series (Eye Joints).............................................................................. 54 For 102, 107, and 114 Engine Series (Taper Screws)............................................................................ 54 ELECTRIC WIRE CODE.................................................................................................................... 55 Classification By Thickness....................................................................................................... 55 Classification By Color And Code.................................................................................................. 55 How To Read Electric Wire Code.................................................................................................... 56 PRECAUTIONS FOR OPERATIONS............................................................................................................ 59 Precautions when Carrying Out Removal Work........................................................................................ 59 Precautions when Carrying Out Installation Work................................................................................... 60 Precautions when Completing the Operation......................................................................................... 61 CONVERSION TABLES..................................................................................................................... 62 Method Of Using The Conversion Table.............................................................................................. 62 COATING MATERIALS..................................................................................................................... 68 LIST OF ABBREVIATIONS................................................................................................................. 70 List of Abbreviations Used in the Shop Manual..................................................................................... 70 List of Abbreviations Used in the Circuit Diagrams................................................................................ 74 01 GENERAL................................................................................................................................ 75 SPECIFICATION DIMENSION DRAWINGS...................................................................................................... 76 Dimensions........................................................................................................................ 76 Working Ranges.................................................................................................................... 77 SPECIFICATIONS........................................................................................................................ 78 Engine............................................................................................................................ 78 Undercarriage..................................................................................................................... 78 Hydraulic System.................................................................................................................. 79 WEIGHT TABLE.......................................................................................................................... 82 FUEL, COOLANT AND LUBRICANTS.......................................................................................................... 84 Lubrication Chart................................................................................................................. 86 10 STRUCTION AND FUNCTION................................................................................................................. 87 ENGINE AND COOLING SYSTEM............................................................................................................. 90 Engine Related Parts.............................................................................................................. 90 Cooling System.................................................................................................................... 92 POWER TRAIN........................................................................................................................... 94 Power Train....................................................................................................................... 94 Swing Circle...................................................................................................................... 96 Final Drive....................................................................................................................... 98 PC360LC-10.................................................................................................................... 98 PC390LC-10.................................................................................................................... 100 UNDERCARRIAGE AND FRAME............................................................................................................... 102 Track Frame and Idler Cushion..................................................................................................... 102 HYDRAULIC SYSTEM...................................................................................................................... 104 Hydraulic Component Layout........................................................................................................ 104 Valve Control..................................................................................................................... 106 Hydraulic Tank.................................................................................................................... 108 Oil Filler Cap.................................................................................................................... 109 CLSS.............................................................................................................................. 110 Structure of CLSS............................................................................................................. 110 Basic principle............................................................................................................... 111 Main Pump......................................................................................................................... 114 Operation..................................................................................................................... 118 LS Valve...................................................................................................................... 120 PC Valve...................................................................................................................... 126 LS(PC)-EPC Valve.............................................................................................................. 133 Control Valve..................................................................................................................... 136 Functions and Operation by Valve.................................................................................................. 148 Hydraulic Circuit Diagram and Name of Valves.................................................................................. 148 Unload Valve.................................................................................................................. 152 Introduction of LS Pressure................................................................................................... 153 LS By-Pass Plug............................................................................................................... 154 Pressure Compensation Valve................................................................................................... 155 Shuttle Valve In Pressure Compensation Valve.................................................................................. 158 Boom Regeneration Circuit..................................................................................................... 160 Arm Regeneration Circuit...................................................................................................... 162 Merge-Divider Valve........................................................................................................... 164 LS Selector Valve............................................................................................................. 167 Self-Pressure Reducing Valve.................................................................................................. 168 Travel Junction Valve......................................................................................................... 172 Travel PPC Shuttle Valve...................................................................................................... 176 Boom Hydraulic Drift Prevention Valve......................................................................................... 178 Arm Hydraulic Drift Prevention Valve (If Equipped)............................................................................ 181 Suction Safety Valve for Drift Prevention Valve............................................................................... 184 Arm Quick Return Valve........................................................................................................ 186 Variable Back Pressure Valve.................................................................................................. 188 Main Relief Valve............................................................................................................. 190 Suction 2-Stage Safety Valve.................................................................................................. 192 Swing Motor....................................................................................................................... 194 Swing Holding Brake........................................................................................................... 196 Relief Valve.................................................................................................................. 198 Swing 2-Stage Relief Valve.................................................................................................... 200 Swing Motor Reverse Prevention Valve.......................................................................................... 201 Travel Motor - Type KMV180ADT-2 (PC360LC-10)...................................................................................... 204 Operation of Travel Motor..................................................................................................... 207 Operation of Parking Brake.................................................................................................... 209 Brake Valve................................................................................................................... 210 Counterbalance Valve.......................................................................................................... 211 Suction Safety Valve.......................................................................................................... 213 Travel Motor - Type KMV200ADT-2 (PC390LC-10)...................................................................................... 216 Operation of Travel Motor..................................................................................................... 219 Parking Brake................................................................................................................. 222 Brake Valve................................................................................................................... 224 Safety Valve.................................................................................................................. 226 PPC Valve......................................................................................................................... 230 Work Equipment and Swing PPC Valve............................................................................................ 230 Travel PPC Valve.............................................................................................................. 236 1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped).................................................................. 240 EPC Valve (If Equipped)....................................................................................................... 242 2nd-Line Attachment PPC Valve (If Equipped)................................................................................... 246 Solenoid Valve.................................................................................................................... 248 Attachment Circuit Selector Valve (If Equipped)................................................................................... 252 Center Swivel Joint............................................................................................................... 254 Accumulator....................................................................................................................... 256 PPC Accumulator............................................................................................................... 256 WORK EQUIPMENT........................................................................................................................ 258 Work Equipment.................................................................................................................... 258 Work Equipment Shim............................................................................................................... 259 Bucket Play Adjustment Shim....................................................................................................... 259 CAB AND ITS ATTACHMENTS............................................................................................................... 260 Cab Mount and Cab Tipping Stopper................................................................................................. 260 ROPS Cab.......................................................................................................................... 262 ELECTRICAL SYSTEM..................................................................................................................... 264 Electrical Control System......................................................................................................... 264 Machine Control System Diagram................................................................................................ 264 Engine Control Function....................................................................................................... 266 Engine and Pump Combined Control Function..................................................................................... 268 Pump and Valve Control Function............................................................................................... 274 One-Touch Power Maximizing Function........................................................................................... 276 Machine Push-Up Function...................................................................................................... 278 Auto-Deceleration Function.................................................................................................... 280 Engine Automatic Warm-Up Function............................................................................................. 282 Overheat Prevention Function.................................................................................................. 284 Turbocharger Protection Function.............................................................................................. 285 Swing Control Function........................................................................................................ 286 Quick Warm-Up Function........................................................................................................ 288 Swing 2-Stage Relief Function................................................................................................. 288 Travel Control Function....................................................................................................... 290 PPC Lock Function............................................................................................................. 292 Attachment Flow Control Function.............................................................................................. 294 System Component Part............................................................................................................. 296 Engine Controller............................................................................................................. 296 Pump Controller............................................................................................................... 300 Fuel Control Dial............................................................................................................. 304 Resister for PC-EPC valve..................................................................................................... 305 CAN Terminating Resistor...................................................................................................... 306 Engine Oil Pressure Switch.................................................................................................... 307 PPC Oil Pressure Switch....................................................................................................... 308 MACHINE MONITOR SYSTEM................................................................................................................ 310 Machine Monitor................................................................................................................... 312 Input and Output Signals...................................................................................................... 313 Display....................................................................................................................... 316 Gauges........................................................................................................................ 318 Caution Monitor............................................................................................................... 320 Pilot Monitor................................................................................................................. 324 Switches.......................................................................................................................... 326 Guidance ICON and Function Switch............................................................................................. 328 Operator Mode Function........................................................................................................ 332 Service Mode Function......................................................................................................... 334 KOMTRAX SYSTEM........................................................................................................................ 336 KOMTRAX terminal.................................................................................................................. 337 Input and Output Signals.......................................................................................................... 338 SENSORS............................................................................................................................... 340 Ambient Pressure Sensor........................................................................................................... 340 Charge (Boost) Pressure and Temperature Sensor.................................................................................... 341 Coolant Temperature Sensor........................................................................................................ 342 Ne (Crankshaft) Speed Sensor...................................................................................................... 342 Bkup (Camshaft) Speed Sensor...................................................................................................... 343 Common Rail Pressure Sensor....................................................................................................... 343 Exhaust Manifold Pressure Sensor.................................................................................................. 344 EGR Orifice Temperature Sensor.................................................................................................... 344 EGR Valve Lift Sensor............................................................................................................. 345 Turbo Speed Sensor................................................................................................................ 346 KVGT Position Sensor.............................................................................................................. 347 Mass Air Flow and Temperature Sensor.............................................................................................. 348 KDPF Differential Pressure and Outlet Pressure Sensor............................................................................. 348 KDOC Inlet Temperature Sensor..................................................................................................... 349 KDOC Outlet Temperature Sensor.................................................................................................... 349 KDPF Outlet Temperature Sensor.................................................................................................... 350 Crankcase Pressure Sensor......................................................................................................... 350 Engine Oil Level Sensor........................................................................................................... 351 Fuel Level Sensor................................................................................................................. 352 Coolant Level Sensor.............................................................................................................. 353 Hydraulic Oil Temperature Sensor.................................................................................................. 353 Front Pump Oil Pressure Sensor.................................................................................................... 354 Rear Pump Oil Pressure Sensor..................................................................................................... 355 PPC Oil Pressure Sensor........................................................................................................... 356 Air Cleaner Clogging Sensor....................................................................................................... 357 Front Pump Swash Plate Sensor..................................................................................................... 358 Rear Pump Swash Plate Sensor...................................................................................................... 360 Water-In-Fuel Sensor.............................................................................................................. 362 20 STANDARD VALUE TABLES.................................................................................................................. 363 STANDARD SERVICE VALUE TABLES......................................................................................................... 364 Standard Value Table for Engine Related Parts..................................................................................... 364 Standard Value Table for Chassis Related Parts.................................................................................... 366 Engine Speed.................................................................................................................. 366 Travel of Control Valve Spool................................................................................................. 366 Travel of Control Lever....................................................................................................... 367 Operating Effort of Control Lever and Pedal................................................................................... 367 Hydraulic Pressure............................................................................................................ 368 Swing......................................................................................................................... 369 Travel........................................................................................................................ 370 Work Equipment................................................................................................................ 372 Performance in Combined Operation............................................................................................. 374 Pump Swash Plate Sensor....................................................................................................... 374 Main Pump..................................................................................................................... 374 Posture of Machine for Measuring Performance and Measurement Procedure............................................................ 376 Control Valve: Spool Stroke................................................................................................... 376 Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing.......................................... 376 Swing 2: Hydraulic Drift of Swing............................................................................................. 376 Travel 1: Travel Speed, Idle Running (Without Load)........................................................................... 376 Travel 2: Travel Speed (Actual Run), Travel Deviation......................................................................... 377 Travel 3: Travel Deviation.................................................................................................... 377 Travel 4: Hydraulic Drift of Travel........................................................................................... 377 Work Equipment 1: Hydraulic Drift of Work Equipment........................................................................... 377 Work Equipment 2: Boom Speed.................................................................................................. 378 Work Equipment 3: Arm Speed................................................................................................... 378 Work Equipment 4: Bucket Speed................................................................................................ 378 Work Equipment 5: Boom Time Lag............................................................................................... 378 Work Equipment 6: Arm Time Lag................................................................................................ 379 Work Equipment 7: Bucket Time Lag............................................................................................. 379 30 TESTING AND ADJUSTING.................................................................................................................. 381 GENERAL INFORMATION................................................................................................................... 386 Tools for Testing, Adjusting, and Troubleshooting................................................................................. 386 Sketch of Tools for Testing and Adjusting......................................................................................... 393 ENGINE AND COOLING SYSTEM............................................................................................................. 396 Checking Engine Speed............................................................................................................. 396 Measuring Boost Pressure.......................................................................................................... 398 Measuring Exhaust Gas Color....................................................................................................... 402 Measuring and Adjusting Valve Clearance........................................................................................... 404 Testing....................................................................................................................... 404 Adjustment.................................................................................................................... 407 Measuring Compression Pressure.................................................................................................... 410 Measuring Blow-By Pressure........................................................................................................ 420 Measuring Engine Oil Pressure..................................................................................................... 422 Measuring EGR Valve and KVGT Oil Pressure......................................................................................... 426 Measuring Fuel Pressure........................................................................................................... 428 Testing Low-Pressure Circuit (Main Fuel Filter Inlet Side).................................................................... 430 Testing Low-Pressure Circuit (Pressure Difference)............................................................................ 431 Testing Return Circuit........................................................................................................ 432 Testing the Negative Pressure Circuit (At Fuel Supply Connector).............................................................. 434 Testing the Negative Pressure Circuit (At Supply Pump)........................................................................ 435 Testing Fuel Feed Pump Outlet Pressure (At Supply Pump)....................................................................... 436 Measuring Fuel Delivery, Return and Leakage....................................................................................... 437 Testing Supply Pump Delivery.................................................................................................. 438 Testing Supply Pump Return Rate............................................................................................... 440 Testing Leakage from Pressure Limiter......................................................................................... 442 Measuring Return Rate from Injector........................................................................................... 443 Testing Delivery of Fuel Feed Pump............................................................................................ 444 Bleeding Air from Fuel System..................................................................................................... 445 Bleeding Air.................................................................................................................. 445 Checking Fuel Circuit for Leakage................................................................................................. 446 Handling Cylinder Cut-Out Mode Operation.......................................................................................... 447 Handling No-Injection Cranking Operation.......................................................................................... 447 Checking and Adjusting Air Conditioner Compressor Belt Tension.................................................................... 448 Checking...................................................................................................................... 448 Adjusting..................................................................................................................... 448 Replacing Fan Belt................................................................................................................ 449 Replacing Alternator Belt......................................................................................................... 450 POWER TRAIN........................................................................................................................... 452 Testing Swing Circle Bearing Clearance............................................................................................ 452 Testing....................................................................................................................... 452 UNDERCARRIAGE AND FRAME............................................................................................................... 454 Testing and Adjusting Track Shoe Tension.......................................................................................... 454 Testing....................................................................................................................... 454 Adjusting..................................................................................................................... 454 HYDRAULIC SYSTEM...................................................................................................................... 456 Releasing Remaining Pressure from Hydraulic Circuit............................................................................... 456 Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits............................................. 458 Testing....................................................................................................................... 458 Measuring Method by Using Machine Monitor..................................................................................... 458 Measuring Method by Using Oil Pressure Gauge.................................................................................. 460 Combination of Pump, Actuator, and Valve...................................................................................... 462 Measuring Unload Pressure..................................................................................................... 462 Measuring Work Equipment Relief Pressure...................................................................................... 462 Measuring Swing Relief Pressure............................................................................................... 463 Measuring Travel Relief Pressure.............................................................................................. 463 Work After Finishing Measurement.............................................................................................. 463 Adjusting..................................................................................................................... 464 Adjusting Work Equipment and Travel Relief Pressure........................................................................... 464 Adjusting Boom LOWER Relief Pressure (On the Side Where High Pressure is Set)................................................. 465 Adjusting Boom LOWER Relief Pressure (On the Side Where Low Pressure is Set).................................................. 466 Adjusting Swing Relief Pressure............................................................................................... 467 Measuring Oil Pressure in Control Circuit......................................................................................... 468 Measuring with Machine Monitor................................................................................................ 468 Measuring with Oil Pressure Gauge............................................................................................. 472 Measuring and Adjusting Oil Pressure in Pump PC Control Circuit................................................................... 474 Testing....................................................................................................................... 475 Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor......................................... 475 Measuring PC-EPC Valve Output Pressure With the Machine Monitor............................................................... 478 Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Oil Pressure Gauge...................................... 482 Measuring PC-EPC Valve Output Pressure With Oil Pressure Gauge................................................................ 486 Adjusting..................................................................................................................... 488 Measuring and Adjusting Oil Pressure in Pump LS Control Circuit................................................................... 489 Testing....................................................................................................................... 490 Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor......................................... 490 Measuring LS Differential Pressure with the Machine Monitor................................................................... 494 Measuring LS-EPC Valve Output Pressure with the Machine Monitor............................................................... 498 Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) with Oil Pressure Gauge...................................... 500 Measuring LS Differential Pressure with Oil Pressure Gauge.................................................................... 504 Measuring LS-EPC Valve Output Pressure with Oil Pressure Gauge................................................................ 508 Adjusting..................................................................................................................... 509 Measuring Solenoid Valve Output Pressure.......................................................................................... 510 Testing....................................................................................................................... 511 Measuring with Machine Monitor................................................................................................ 511 Measuring with Oil Pressure Gauge............................................................................................. 512 Operating Condition........................................................................................................... 514 Measuring PPC Valve Output Pressure............................................................................................... 516 Testing....................................................................................................................... 516 Measuring with Machine Monitor................................................................................................ 516 Measuring with Oil Pressure Gauge............................................................................................. 517 Adjusting Play of Work Equipment and Swing PPC Valves............................................................................. 519 Adjusting..................................................................................................................... 519 Testing Pump Swash Plate Sensor................................................................................................... 520 Testing Output Voltage of Pump Swash Plate Sensor............................................................................. 520 Isolating the Parts Causing Hydraulic Drift in Work Equipment................................................................. 522 Measuring Oil Leakage............................................................................................................. 524 Bleeding Air From Hydraulic Circuit............................................................................................... 528 CAB AND ITS ATTACHMENTS............................................................................................................... 532 Checking Cab Tipping Stopper...................................................................................................... 532 Adjusting Mirrors................................................................................................................. 534 ELECTRICAL SYSTEM..................................................................................................................... 538 Special Functions of Machine Monitor.............................................................................................. 538 Upper Part of machine monitor (display portion)............................................................................... 539 Upper Part of Machine Monitor (Switch Portion)................................................................................ 539 Lower Part of Machine Monitor (Switch Portion)................................................................................ 539 Ordinary Functions and Special Functions of Machine Monitor....................................................................... 539 Operator Mode (Outline)....................................................................................................... 542 Service Mode.................................................................................................................. 562 Angle Adjustment of Rear View Camera.............................................................................................. 630 Handling Voltage Circuit of Engine Controller..................................................................................... 632 Handling Battery Disconnect Switch................................................................................................ 633 Testing Diodes.................................................................................................................... 634 PM CLINIC............................................................................................................................. 636 PM Clinic Service................................................................................................................. 636 Check Items Related to Engine................................................................................................. 638 Check Items Related to Oil Pressure........................................................................................... 639 Check Sheet....................................................................................................................... 640 40 TROUBLESHOOTING........................................................................................................................ 647 GENERAL INFORMATION ON TROUBLESHOOTING................................................................................................ 656 Points to Remember When Troubleshooting........................................................................................... 656 Sequence of Events in Troubleshooting............................................................................................. 658 Checks Before Troubleshooting..................................................................................................... 660 Testing Procedure Before Troubleshooting.......................................................................................... 662 Walk-Around Check............................................................................................................. 662 Checking in Accordance with Checking Procedure................................................................................ 664 Preparation Work for Troubleshooting of Electrical System......................................................................... 670 Preparation Work.............................................................................................................. 670 Classification and Procedure for Troubleshooting.................................................................................. 675 Classification of Troubleshooting............................................................................................. 675 Procedure for Troubleshooting................................................................................................. 675 Symptom of Probable Failure and Troubleshooting No................................................................................ 679 Information Mentioned in Troubleshooting Table.................................................................................... 683 Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System........................................................ 685 Connector list.................................................................................................................... 688 Layout of connectors.............................................................................................................. 693 Connection Table for Connector Pin Numbers........................................................................................ 699 T-Branch Box and T-Branch Adapter Table........................................................................................... 734 Fuse List and Location............................................................................................................ 738 Connection Table of Fuse Box.................................................................................................. 738 Locations of Fusible Links.................................................................................................... 739 Location of Fuse Box and Fuse Numbers......................................................................................... 739 Precautions for Cleaning and Replacing KDPF (KCSF, KDOC).......................................................................... 740 FAILURE CODE (DISPLAY OF CODE)........................................................................................................ 743 Failure Codes Table............................................................................................................... 743 879AKA - A/C Inner Sensor Open Circuit............................................................................................ 750 879AKB - A/C Inner Sensor Short Circuit........................................................................................... 750 879BKA - A/C Outer Sensor Open Circuit............................................................................................ 750 879BKB - A/C Outer Sensor Short Circuit........................................................................................... 750 879CKA - Ventilating Sensor Open Circuit.......................................................................................... 750 879CKB - Ventilating Sensor Short Circuit......................................................................................... 750 879DKZ - Sunlight Sensor Open or Short Circuit.................................................................................... 750 879EMC - Ventilation Damper Abnormality........................................................................................... 751 879FMC - Air Mix Damper Abnormality............................................................................................... 751 879GKX - Refrigerant Abnormality.................................................................................................. 751 989L00 - Engine Controller Lock Caution 1......................................................................................... 752 989M00 - Engine Controller Lock Caution 2......................................................................................... 752 989N00 - Engine Controller Lock Caution 3......................................................................................... 753 A1U0N3 - KDPF Dry Request (HC Release) 1.......................................................................................... 754 A1U0N4 - KDPF Dry Request (HC Release) 2.......................................................................................... 756 AA10NX - Air Cleaner Clogging..................................................................................................... 758 AB00KE - Charge Voltage Low....................................................................................................... 760 B@BAZG - Engine Oil Pressure Low.................................................................................................. 762 B@BAZK - Eng Oil Level Low........................................................................................................ 764 B@BCNS - Engine Coolant Overheat.................................................................................................. 766 B@BCZK - Radiator Coolant Level Low............................................................................................... 768 B@HANS - Hyd Oil Overheat......................................................................................................... 770 CA115 - Eng Ne and Bkup Speed Sens Error.......................................................................................... 771 CA122 - Chg Air Press Sensor High Error........................................................................................... 772 CA123 - Chg Air Press Sensor Low Error............................................................................................ 774 CA131 - Throttle Sensor High Error................................................................................................ 776 CA132 - Throttle Sensor Low Error................................................................................................. 778 CA144 - Coolant Temp Sens High Error.............................................................................................. 780 CA145 - Coolant Temp Sens Low Error............................................................................................... 782 CA153 - Chg Air Temp Sensor High Error............................................................................................ 784 CA154 - Chg Air Temp Sensor Low Error............................................................................................. 786 CA187 - Sensor 2 Supply Volt Low Error............................................................................................ 788 CA221 - Ambient Press Sensor High Error........................................................................................... 790 CA222 - Ambient Press Sensor Low Error............................................................................................ 792 CA227 - Sensor 2 Supply Volt High Error........................................................................................... 794 CA234 - Eng Overspeed............................................................................................................. 795 CA238 - Ne Speed Sensor Supply Volt Error......................................................................................... 796 CA239 - Ne Speed Sens Supply Volt High Error...................................................................................... 798 CA271 - IMV/PCV1 Short Error...................................................................................................... 800 CA272 - IMV/PCV1 Open Error....................................................................................................... 802 CA281 - Pump Press Balance Error.................................................................................................. 804 CA295 - Ambient Press Sens In Range Error......................................................................................... 805 CA322 - Inj #1 (L#1) Open/Short Error............................................................................................. 806 CA323 - Inj #5 (L#5) Open/Short Error............................................................................................. 808 CA324 - Inj #3 (L#3) Open/Short Error............................................................................................. 810 CA325 - Inj #6 (L#6) Open/Short Error............................................................................................. 812 CA331 - Inj #2 (L#2) Open/Short Error............................................................................................. 814 CA332 - Inj #4 (L#4) Open/Short Error............................................................................................. 816 CA343 - ECM Critical Internal Failure............................................................................................. 818 CA351 - Injectors Drive Circuit Error............................................................................................. 819 CA352 - Sensor 1 Supply Volt Low Error............................................................................................ 820 CA356 - Mass Air Flow Sensor High Error........................................................................................... 822 CA357 - Mass Air Flow Sensor Low Error............................................................................................ 824 CA386 - Sensor 1 Supply Volt High Error........................................................................................... 827 CA428 - Water in Fuel Sensor High Error........................................................................................... 828 CA429 - Water in Fuel Sensor Low Error............................................................................................ 830 CA435 - Eng Oil Press Sw Error.................................................................................................... 832 CA441 - Battery Voltage Low Error................................................................................................. 834 CA442 - Battery Voltage High Error................................................................................................ 836 CA449 - Rail Press Very High Error................................................................................................ 837 CA451 - Rail Press Sensor High Error.............................................................................................. 840 CA452 - Rail Press Sensor Low Error............................................................................................... 842 CA488 - Chg Air Temp High Torque Derate........................................................................................... 844 CA515 - Rail Press Sens Sup Volt High Error....................................................................................... 846 CA516 - Rail Press Sens Sup Volt Low Error........................................................................................ 848 CA553 - Rail Press High Error 1................................................................................................... 850 CA555 - Crankcase Press High Error 1.............................................................................................. 851 CA556 - Crankcase Press High Error 2.............................................................................................. 852 CA559 - Rail Press Low Error 1.................................................................................................... 853 CA595 - Turbo Speed High Error 2.................................................................................................. 857 CA687 - Turbo Speed Low Error..................................................................................................... 858 CA689 - Eng Ne Speed Sensor Error................................................................................................. 860 CA691 - Intake Air Temp Sens High Error........................................................................................... 864 CA692 - Intake Air Temp Sens Low Error............................................................................................ 866 CA697 - ECM Int Temp Sensor High Error............................................................................................ 868 CA698 - ECM Int Temp Sensor Low Error............................................................................................. 869 CA731 - Eng Bkup Speed Sens Phase Error........................................................................................... 870 CA778 - Eng Bkup Speed Sensor Error............................................................................................... 872 CA1117 - Persistent Data Lost Error............................................................................................... 876 CA1664 - KDOC Malfunction......................................................................................................... 878 CA1691 - Regeneration Ineffective................................................................................................. 880 CA1695 - Sensor 5 Supply Volt High Error.......................................................................................... 884 CA1696 - Sensor 5 Supply Volt Low Error........................................................................................... 886 CA1843 - Crankcase Press Sens High Error.......................................................................................... 888 CA1844 - Crankcase Press Sens Low Error........................................................................................... 890 CA1879 - KDPF Differential P Sensor High Error.................................................................................... 892 CA1881 - KDPF Differential P Sensor Low Error..................................................................................... 894 CA1883 - KDPF Differential P Sens In Range Error.................................................................................. 896 CA1921 - KDPF Soot Load High Error 1.............................................................................................. 900 CA1922 - KDPF Soot Load High Error 2.............................................................................................. 902 CA1942 - Crankcase Press Sens In Range Error...................................................................................... 906 CA1993 - KDPF Differential Pressure Low Error..................................................................................... 907 CA2185 - Throt Sensor Sup Volt High Error......................................................................................... 908 CA2186 - Throt Sensor Sup Volt Low Error.......................................................................................... 910 CA2249 - Rail Press Very Low Error................................................................................................ 912 CA2265 - Fuel Feed Pump Open Error................................................................................................ 914 CA2266 - Fuel Feed Pump Short Error............................................................................................... 916 CA2271 - EGR Valve Pos Sens High Error............................................................................................ 918 CA2272 - EGR Valve Pos Sens Low Error............................................................................................. 922 CA2288 - Turbo Speed High Error 1................................................................................................. 925 CA2311 - IMV Solenoid Error....................................................................................................... 926 CA2349 - EGR Valve Solenoid Open Error............................................................................................ 927 CA2353 - EGR Valve Solenoid Short Error........................................................................................... 929 CA2357 - EGR Valve Servo Error.................................................................................................... 931 CA2373 - Exhaust Manifold Press Sens High error................................................................................... 932 CA2374 - Exhaust Manifold Press Sens Low Error.................................................................................... 934 CA2375 - EGR Orifice Temp Sens High Error......................................................................................... 936 CA2376 - EGR Orifice Temp Sens Low Error.......................................................................................... 938 CA2381 - KVGT Pos Sens High Error................................................................................................. 940 CA2382 - KVGT Pos Sens Low Error.................................................................................................. 942 CA2383 - KVGT Solenoid Open Error................................................................................................. 946 CA2386 - KVGT Solenoid Short Error................................................................................................ 948 CA2387 - KVGT Valve Servo Error................................................................................................... 950 CA2554 - Exh Manifold Press Sens In Range Error................................................................................... 951 CA2555 - Grid Htr Relay Open Circuit Error........................................................................................ 952 CA2556 - Grid Htr Relay Volt High Error........................................................................................... 954 CA2637 - KDOC Blocked............................................................................................................. 956 CA2639 - Manual Stationary Regeneration Request................................................................................... 958 CA2961 - EGR Orifice Temp High Error 1............................................................................................ 960 CA2973 - Chg Air Press Sensor In Range Error...................................................................................... 961 CA3133 - KDPF Outlet Press Sens High Error........................................................................................ 962 CA3134 - KDPF Outlet Press Sens Low Error......................................................................................... 964 CA3135 - KDPF Outlet Press Sens In Range Error.................................................................................... 966 CA3251 - KDOC Inlet Temp High Error............................................................................................... 970 CA3253 - KDOC Temp Error - Non Regeneration....................................................................................... 974 CA3254 - KDOC Outlet Temp High Error 1............................................................................................ 976 CA3255 - KDPF Temp Error - Non Regeneration....................................................................................... 979 CA3256 - KDPF Outlet Temp High Error 1............................................................................................ 980 CA3311 - KDOC Outlet Temp High Error 2............................................................................................ 981 CA3312 - KDPF Outlet Temp High Error 2............................................................................................ 982 CA3313 - KDOC Inlet Temp Sensor Low Error......................................................................................... 986 CA3314 - KDOC Inlet Temp Sens High Error.......................................................................................... 990 CA3315 - KDOC Inlet Temp Sens In Range Error...................................................................................... 994 CA3316 - KDOC Outlet Temp Sens Low Error.......................................................................................... 998 CA3317 - KDOC Outlet Temp Sens High Error.........................................................................................1002 CA3318 - KDOC Outlet Temp Sens In Range Error.....................................................................................1006 CA3319 - KDPF Outlet Temp Sens High Error.........................................................................................1010 CA3321 - KDPF Outlet Temp Sens Low Error..........................................................................................1014 CA3322 - KDPF Outlet Temp Sens In Range Error.....................................................................................1018 CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error...........................................................................1022 CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error............................................................................1024 CA3741 - Rail Press Valve Trip Error..............................................................................................1026 D110KB - Battery Relay Output Voltage.............................................................................................1028 D19JKZ - Personal Code Relay Abnormality..........................................................................................1030 D811MC - KOMTRAX Error............................................................................................................1033 D862KA - GPS Antenna Open Circuit.................................................................................................1033 D8AQKR - CAN2 Discon (KOMTRAX)....................................................................................................1034 DA20MC - Pump Controller..........................................................................................................1035 DA22KK - Pump Solenoid Power Low Error............................................................................................1036 DA25KP - 5 V Sensor 1 Power Abnormality...........................................................................................1039 DA29KQ - Model Selection Abnormality..............................................................................................1042 DA2QKR - CAN2 Discon ( Pump Con)..................................................................................................1044 DA2RKR - CAN1 Discon ( Pump Con)..................................................................................................1047 DAF0MB - Monitor Memory Error.....................................................................................................1048 DAF0MC - Monitor Error............................................................................................................1049 DAF8KB - Camera Power Supply Short Circuit........................................................................................1050 DAF9KQ - Model Selection Abnormality..............................................................................................1052 DAFGMC - GPS Module Error.........................................................................................................1053 DAFQKR - CAN2 Discon..............................................................................................................1054 DAZ9KQ - A/C Model Selection Abnormality..........................................................................................1055 DAZQKR - CAN2 Discon (AC).........................................................................................................1056 DB2QKR - CAN2 Discon (Engine Con).................................................................................................1060 DB2RKR - CAN1 Discon (Engine Con).................................................................................................1066 DGH2KB - Hyd Oil Sensor Short Circuit.............................................................................................1072 DHA4KA - Air Cleaner Clog Sensor Open Circuit.....................................................................................1074 DHPAMA - F Pump Press Sensor Abnormality..........................................................................................1075 DHPBMA - R Pump Press Sensor Abnormality..........................................................................................1078 DHS3MA - Arm In PPC Press Sensor Abnormality......................................................................................1082 DHS4MA - Bucket Curl PPC Press Sensor Abnormality.................................................................................1086 DHS8MA - Boom Raise PPC Press Sensor Abnormality..................................................................................1090 DHS9MA - Boom Lower PPC Press Sensor Abnormality..................................................................................1094 DHSAMA - Swing RH PPC Press Sensor Abnormality....................................................................................1098 DHSBMA - Swing LH PPC Press Sensor Abnormality....................................................................................1102 DHSCMA - Arm Out PPC Press Sensor Abnormality.....................................................................................1106 DHSDMA - Bucket Dump PPC Press Sensor Abnormality.................................................................................1110 DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality...............................................................................1114 DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality...............................................................................1118 DHSHMA - Travel Rev LH PPC Press Sensor Abnormality...............................................................................1122 DHSJMA - Travel Rev RH PPC Press Sensor Abnormality...............................................................................1126 DKR0MA - F Pump Swash Plate Sensor Abnormality....................................................................................1130 DKR1MA - R Pump Swash Plate Sensor Abnormality....................................................................................1134 DV20KB - Travel Alarm Short Circuit...............................................................................................1138 DW43KA - Travel Speed Sol Open Circuit............................................................................................1140 DW43KB - Travel Speed Sol Short Circuit...........................................................................................1142 DW45KA - Swing Brake Sol Open Circuit.............................................................................................1144 DW45KB - Swing Brake Sol Short Circuit............................................................................................1148 DW91KA - Travel Junction Sol Open Circuit.........................................................................................1152 DW91KB - Travel Junction Sol Short Circuit........................................................................................1154 DWA2KA - Attachment Sol Open Circuit..............................................................................................1156 DWA2KB - Attachment Sol Short Circuit.............................................................................................1158 DWK0KA - 2-Stage Relief Sol Open Circuit..........................................................................................1160 DWK0KB - 2-Stage Relief Sol Short Circuit.........................................................................................1162 DWK2KA - Variable Back Press Sol Open Circuit.....................................................................................1164 DWK2KB - Variable Back Press Sol Short Circuit....................................................................................1166 DWK8KA - Swing Press C/O Sol Open Circuit.........................................................................................1168 DWK8KB - Swing Press C/O Sol Short Circuit........................................................................................1170 DXA8KA - PC-EPC (F) Sol Open Circuit..............................................................................................1172 DXA8KB - PC-EPC (F) Sol Short Circuit.............................................................................................1174 DXA9KA - PC-EPC (R) Sol Open Circuit..............................................................................................1176 DXA9KB - PC-EPC (R) Sol Short Circuit.............................................................................................1180 DXE0KA - LS-EPC Sol Open Circuit..................................................................................................1182 DXE0KB - LS-EPC Sol Short Circuit.................................................................................................1184 DXE4KA - Attachment Flow EPC Open Circuit.........................................................................................1186 DXE4KB - Attachment Flow EPC Short Circuit........................................................................................1188 DXE5KA - Merge-divide Main Sol Open Circuit.......................................................................................1190 DXE5KB - Merge-divide Main Sol Short Circuit......................................................................................1192 DXE6KA - Merge-divide LS Sol Open Circuit.........................................................................................1194 DXE6KB - Merge-divide LS Sol Short Circuit........................................................................................1196 DY20KA - Wiper Working Abnormality................................................................................................1198 DY20MA - Wiper Parking Abnormality................................................................................................1202 DY2CKB - Washer Drive Short Circuit...............................................................................................1204 DY2DKB - Wiper Drive (Fwd) Short Circuit..........................................................................................1206 DY2EKB - Wiper Drive (Rev) Short Circuit..........................................................................................1208 ELECTRICAL SYSTEM (E-MODE)............................................................................................................1210 E-1 Engine Does Not Start (Engine Does Not Rotate)................................................................................1210 E-2 Manual Pre-Heating System Does Not Work.......................................................................................1218 E-3 Automatic Pre-Heating System Does Not Work....................................................................................1222 E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated.............................................................1224 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...............................................1226 E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow..........1229 E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow....1229 E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running........................................................1230 E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running..................................................1230 E-10 Charge Level Monitor Lights Up While Engine is Running.......................................................................1231 E-11 Fuel Level Monitor Lights Up in Red While Engine is Running..................................................................1231 E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running.....................................................1231 E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running..................................................1232 E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...................................................1232 E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running.........................................................1233 E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum.....................................................................1234 E-17 Display of Fuel Gauge Differs from Actual Fuel Level.........................................................................1236 E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move.......................................................1237 E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move.................................................1240 E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature..........................................................1242 E-22 Machine Monitor Does Not Display Partially...................................................................................1243 E-23 Function Switch Does Not Work................................................................................................1243 E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather).................................................................1244 E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated.....................1245 E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated.........................................................1246 E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated..........................1247 E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed................................................1247 E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated....................................................1247 E-32 Travel Speed Does Not Change When Travel Speed is Shifted....................................................................1248 E-31 Alarm Buzzer Does Not Stop Sounding..........................................................................................1249 E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed...........................................................1249 E-33 Machine Monitor Service Mode Cannot be Selected..............................................................................1250 E-34 Any of Work Equipment, Swing and Travel Does Not Work........................................................................1252 E-35 Any of Work Equipment, Swing and Travel Can Not be Locked....................................................................1254 E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled............................................................1256 E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position.......................................1258 E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed..........................................1260 E-39 One-Touch Power Maximizing Function Cannot be Released.......................................................................1263 E-40 Travel Alarm Does Not Sound When Machine Travels.............................................................................1264 E-41 Travel Alarm Does Not Stop Sounding When Machine Stops.......................................................................1266 E-42 Horn Does Not Sound..........................................................................................................1268 E-43 Horn Does Not Stop Sounding..................................................................................................1270 E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated......................................................1271 E-45 Wiper Does Not Operate When Wiper Switch is Operated.........................................................................1272 E-46 Window Washer Does Not Operate When Window Washer Switch is Operated.........................................................1274 E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function.....................................................1274 E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function.......................................................1274 E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function.........................................................1274 E-50 BooM RAISE Indication is Not Displayed Properly With Monitoring Function.....................................................1275 E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function....................................................1275 E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function....................................................1275 E-53 Swing Indication is Not Displayed Properly With Monitoring Function..........................................................1275 E-54 Travel Indication is Not Displayed Properly With Monitoring Function.........................................................1276 E-55 Attachment is Not Displayed Properly With Monitoring Function................................................................1277 E-56 Attachment Hydraulic Circuit Cannot be Changed...............................................................................1280 E-57 KOMTRAX System Does Not Work Properly........................................................................................1282 E-58 Machine Push-up Function is Not Canceled.....................................................................................1284 HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)..............................................................................................1288 Information Mentioned in Troubleshooting Table (H Mode)...........................................................................1288 Failure Mode and Cause Table......................................................................................................1290 H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power........................................................1299 H-2 Engine Speed Lowers Significantly or Engine Stalls............................................................................1304 H-3 Any of Work Equipment, Swing and Travel Does Not Work.........................................................................1307 H-4 Unusual Sound is Heard from Around Hydraulic Pump.............................................................................1307 H-5 Fine Control Performance or Response is Poor..................................................................................1308 H-6 Boom Operation Lacks Speed or Power...........................................................................................1310 H-7 Arm Operation Lacks Speed or Power............................................................................................1315 H-8 Bucket Operation Lacks Speed or Power.........................................................................................1320 H-9 Work Equipment Does Not Move in Single Operation..............................................................................1324 H-10 Hydraulic Drift of Boom is Large.............................................................................................1325 H-11 Hydraulic Drift of Arm is Large..............................................................................................1326 H-12 Hydraulic Drift of Bucket is Large...........................................................................................1328 H-13 Time Lag of Work Equipment is Large..........................................................................................1330 H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move...........................................1332 H-15 One-Touch Power Maximizing Function Does Not Work............................................................................1333 H-16 Machine Push Up Function Does Not Work.......................................................................................1334 H-17 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower..........................................1335 H-18 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low.....................................................1336 H-19 In Combined Operations of Swing and Travel, Travel Speed Drops Largely.......................................................1336 H-20 Machine Does Not Travel Straight.............................................................................................1337 H-21 Travel Speed is Too Low......................................................................................................1340 H-22 Machine is hard to Steer or Travel Power is Low..............................................................................1342 H-23 Travel Speed Does Not Change, or Travel Speed is Too Low or High.............................................................1346 H-24 One of Tracks Dose Not Run...................................................................................................1348 H-25 Upper Structure Does Not Swing to the Right or Left..........................................................................1350 H-26 Upper Structure Swing Only to the Right or Left..............................................................................1351 H-27 Swing Acceleration is Poor or Swing Speed is Low (Either Right and Left).....................................................1352 H-28 Swing Aceleration is Poor or Swing Speed is Low in Only One Direction........................................................1354 H-29 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)............................................1355 H-30 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)...........................................1356 H-31 Shock is Large When Upper Structure Stops Swinging...........................................................................1357 H-32 Large Unusual Noise is Heard When Upper Structure Stops Swinging.............................................................1358 H-33 When Swing Holding Brake is Applied, Hydraulic Drift of Swing is Large.......................................................1359 H-34 When Swing Holding Brake is Released, Hydraulic Drift Of Swing is Large......................................................1360 H-35 When additional attachment is installed, attachment circuit is not switched..................................................1361 H-36 Oil Flow in Attachment Circuit Cannot be Controlled..........................................................................1362 ENGINE (S-MODE).......................................................................................................................1364 Information Mentioned in Troubleshooting Table (S-Mode)...........................................................................1364 S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank.......................................................1366 S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out...........................................................................1367 S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)....................1368 S-4 Startability is Poor..........................................................................................................1370 S-5 Engine Does Not Pick Up Smoothly..............................................................................................1372 S-6 Engine Stops During Operation.................................................................................................1374 S-7 Engine Runs Rough or is Unstable..............................................................................................1376 S-8 Engine Lacks Power............................................................................................................1378 S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)..................................................................................1380 S-10 Engine Oil Consumption is Excessive..........................................................................................1382 S-11 Oil Becomes Contaminated Early...............................................................................................1383 S-12 Fuel Consumption is Excessive................................................................................................1384 S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down).............................................................1385 S-14 Oil Pressure Drops...........................................................................................................1386 S-15 Fuel is Contaminated in Engine Oil...........................................................................................1388 S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White).......................................................................1389 S-17 Coolant Temperature Rises Too High (Overheating).............................................................................1390 S-18 Unusual Noise is Heard.......................................................................................................1391 S-19 Vibration is Excessive.......................................................................................................1392 S-20 Air Cannot be Bled from Fuel Circuit.........................................................................................1393 S-21 Automatic Regeneration is Operated Frequently................................................................................1394 S-22 Active Regeneration is Operated for Long.....................................................................................1395 S-23 White Smoke Comes Out in the Process of Active Regeneration..................................................................1396 50 DISASSEMBLY AND ASSEMBLY...............................................................................................................1397 HOW TO READ THIS SECTION..............................................................................................................1402 Removal and Installation of Assemblies............................................................................................1402 Special Tools.................................................................................................................1402 Removal.......................................................................................................................1402 Installation..................................................................................................................1402 Disassembly and Assembly of Assemblies............................................................................................1403 Special Tools.................................................................................................................1403 Disassembly...................................................................................................................1403 Assembly......................................................................................................................1404 Coating Materials List............................................................................................................1405 SPECIAL TOOLS LIST....................................................................................................................1410 Sketches of Special Tools.........................................................................................................1414 CONNECTOR REPAIR PROCEDURES...........................................................................................................1417 Stripping Insulation..............................................................................................................1417 Wire Inspection...................................................................................................................1417 Contact Terminal Removal (HD30 Type)..............................................................................................1418 Crimping Contact Terminal (HD30 Type).............................................................................................1419 Insertion of Contact Terminal (HD30 Type).........................................................................................1420 Contact Terminal Removal (DT Type)................................................................................................1421 Crimping Contact Terminal (DT Type)...............................................................................................1422 Insertion of Contact Terminal (DT Type)...........................................................................................1423 ENGINE AND COOLING SYSTEM.............................................................................................................1424 Supply Pump Assembly..............................................................................................................1424 Removal.......................................................................................................................1424 Installation..................................................................................................................1430 Fuel Injector Assembly............................................................................................................1438 Removal.......................................................................................................................1438 Installation..................................................................................................................1447 Cylinder Head Assembly............................................................................................................1460 Removal.......................................................................................................................1460 Installation..................................................................................................................1474 Radiator Assembly.................................................................................................................1492 Removal.......................................................................................................................1492 Installation..................................................................................................................1495 Hydraulic Oil Cooler Assembly.....................................................................................................1496 Removal.......................................................................................................................1496 Installation..................................................................................................................1500 Aftercooler Assembly..............................................................................................................1502 Removal.......................................................................................................................1502 Installation..................................................................................................................1503 Engine and Main Pump Assembly.....................................................................................................1504 Removal.......................................................................................................................1504 Installation..................................................................................................................1518 Engine Front Oil Seal.............................................................................................................1522 Removal.......................................................................................................................1522 Installation..................................................................................................................1526 Engine Rear Oil Seal..............................................................................................................1530 Removal.......................................................................................................................1530 Installation..................................................................................................................1532 Fuel Tank Assembly................................................................................................................1540 Removal.......................................................................................................................1540 Installation..................................................................................................................1543 Engine Hood Assembly..............................................................................................................1544 Removal.......................................................................................................................1544 Installation..................................................................................................................1546 KDPF Assembly.....................................................................................................................1548 Removal.......................................................................................................................1548 Installation..................................................................................................................1554 Disassembly...................................................................................................................1558 Assembly......................................................................................................................1564 KCCV Assembly.....................................................................................................................1570 Removal.......................................................................................................................1570 Installation..................................................................................................................1571 Air Cleaner Assembly..............................................................................................................1572 Removal.......................................................................................................................1572 Installation..................................................................................................................1575 Air Conditioner Compressor Assembly...............................................................................................1576 Removal.......................................................................................................................1576 Installation..................................................................................................................1577 Air Conditioner Condenser Assembly................................................................................................1578 Removal.......................................................................................................................1578 Installation..................................................................................................................1579 POWER TRAIN...........................................................................................................................1580 Travel Motor and Final Drive Assembly.............................................................................................1580 Removal.......................................................................................................................1580 Installation..................................................................................................................1581 Final Drive (PC360LC-10)..........................................................................................................1582 Disassembly...................................................................................................................1582 Assembly......................................................................................................................1587 Final Drive (PC390LC-10)..........................................................................................................1594 Removal.......................................................................................................................1594 Installation..................................................................................................................1594 Disassembly...................................................................................................................1595 Assembly......................................................................................................................1600 Swing Motor and Swing Machinery Assembly (PC360LC-10).............................................................................1608 Removal.......................................................................................................................1608 Installation..................................................................................................................1609 Swing Motor and Swing Machinery (PC390LC-10)......................................................................................1610 Removal.......................................................................................................................1610 Installation..................................................................................................................1611 Swing Machinery (PC360LC-10)......................................................................................................1612 Disassembly...................................................................................................................1612 Assembly......................................................................................................................1616 Swing Machinery (PC390LC-10)......................................................................................................1622 Disassembly...................................................................................................................1622 Assembly......................................................................................................................1626 Swing Circle Assembly (PC360LC-10)................................................................................................1632 Removal.......................................................................................................................1632 Installation..................................................................................................................1632 Swing Circle Assembly (PC390LC-10)................................................................................................1633 Removal.......................................................................................................................1633 Installation..................................................................................................................1633 UNDERCARRIAGE AND FRAME...............................................................................................................1634 Track Shoe Assembly...............................................................................................................1634 Separation....................................................................................................................1634 Installation..................................................................................................................1636 Sprocket..........................................................................................................................1639 Removal.......................................................................................................................1639 Installation..................................................................................................................1639 Idler and Idler Cushion Assembly..................................................................................................1640 Removal.......................................................................................................................1640 Installation..................................................................................................................1640 Idler.............................................................................................................................1641 Disassembly...................................................................................................................1641 Assembly......................................................................................................................1642 Idler Cushion (PC360LC-10)........................................................................................................1646 Disassembly...................................................................................................................1647 Assembly......................................................................................................................1648 Idler Cushion (PC390LC-10)........................................................................................................1650 Disassembly...................................................................................................................1651 Assembly......................................................................................................................1652 Track Roller......................................................................................................................1654 Disassembly...................................................................................................................1654 Assembly......................................................................................................................1656 Carrier Roller....................................................................................................................1658 Disassembly...................................................................................................................1658 Assembly......................................................................................................................1660 Revolving Frame Assembly..........................................................................................................1664 Removal.......................................................................................................................1664 Installation..................................................................................................................1666 Counterweight Assembly............................................................................................................1668 Removal.......................................................................................................................1668 Installation..................................................................................................................1671 HYDRAULIC SYSTEM......................................................................................................................1672 Center Swivel Joint Assembly......................................................................................................1672 Removal.......................................................................................................................1672 Installation..................................................................................................................1674 Disassembly...................................................................................................................1676 Disassembly...................................................................................................................1676 Assembly......................................................................................................................1677 Hydraulic Tank Assembly...........................................................................................................1678 Removal.......................................................................................................................1678 Installation..................................................................................................................1681 Main Pump Assembly................................................................................................................1682 Removal.......................................................................................................................1682 Installation..................................................................................................................1686 Control Valve Assembly............................................................................................................1688 Removal.......................................................................................................................1688 Installation..................................................................................................................1695 Disassembly...................................................................................................................1696 Replacing Procedures of Pressure Compensation Valve Seal......................................................................1697 Assembly......................................................................................................................1698 Work Equipment PPC Valve..........................................................................................................1702 Disassembly...................................................................................................................1702 Assembly......................................................................................................................1703 Travel PPC Valve..................................................................................................................1704 Disassembly...................................................................................................................1704 Assembly......................................................................................................................1705 WORK EQUIPMENT........................................................................................................................1706 Bucket Assembly...................................................................................................................1706 Removal.......................................................................................................................1706 Installation..................................................................................................................1707 Arm Assembly......................................................................................................................1708 Removal.......................................................................................................................1708 Installation..................................................................................................................1709 Work Equipment Assembly...........................................................................................................1710 Removal.......................................................................................................................1710 Installation..................................................................................................................1712 Work Equipment Cylinder...........................................................................................................1714 Disassembly...................................................................................................................1714 Assembly......................................................................................................................1718 CAB AND ITS ATTACHMENTS...............................................................................................................1724 Operator's Cab Assembly...........................................................................................................1724 Removal.......................................................................................................................1724 Installation..................................................................................................................1731 Operator Cab Glass (Fixed Glass)..................................................................................................1732 Removal.......................................................................................................................1733 Installation..................................................................................................................1734 Front Window Assembly.............................................................................................................1744 Removal.......................................................................................................................1744 Installation..................................................................................................................1747 Floor Frame Assembly..............................................................................................................1752 Removal.......................................................................................................................1752 Installation..................................................................................................................1759 Air Conditioner Unit Assembly.....................................................................................................1762 Removal.......................................................................................................................1762 Installation..................................................................................................................1767 Operator's Seat...................................................................................................................1768 Removal.......................................................................................................................1768 Installation..................................................................................................................1770 Seat Belt.........................................................................................................................1772 Removal.......................................................................................................................1772 Installation..................................................................................................................1773 Front Wiper Assembly..............................................................................................................1774 Removal.......................................................................................................................1774 Installation..................................................................................................................1780 ELECTRIC SYSTEM.......................................................................................................................1786 Engine Controller Assembly........................................................................................................1786 Removal.......................................................................................................................1786 Installation..................................................................................................................1788 Pump Controller Assembly..........................................................................................................1790 Removal.......................................................................................................................1790 Installation..................................................................................................................1792 Machine Monitor Assembly..........................................................................................................1794 Removal.......................................................................................................................1794 Installation..................................................................................................................1797 Pump Swash Plate Sensor...........................................................................................................1798 Removal.......................................................................................................................1798 Installation..................................................................................................................1798 Mass Air Flow and Temperature Sensor..............................................................................................1800 Removal.......................................................................................................................1800 Installation..................................................................................................................1801 KOMTRAX Terminal Assembly.........................................................................................................1802 Removal.......................................................................................................................1802 Installation..................................................................................................................1803 60 MAINTENANCE STANDARD...................................................................................................................1805 ENGINE AND COOLING SYSTEM.............................................................................................................1808 Engine Mounts.....................................................................................................................1808 Cooling System....................................................................................................................1810 POWER TRAIN...........................................................................................................................1812 Swing Circle......................................................................................................................1812 Swing Machinery...................................................................................................................1814 Final Drive.......................................................................................................................1816 PC360LC-10....................................................................................................................1816 PC390LC-10....................................................................................................................1818 Sprocket..........................................................................................................................1820 PC360LC-10....................................................................................................................1820 PC390LC-10....................................................................................................................1822 UNDERCARRIAGE AND FRAME...............................................................................................................1824 Track Frame and Idler Cushion.....................................................................................................1824 Idler.............................................................................................................................1826 PC360LC-10....................................................................................................................1826 PC390LC-10....................................................................................................................1828 Track Roller......................................................................................................................1830 PC360LC-10....................................................................................................................1830 PC390LC-10....................................................................................................................1832 Carrier Roller....................................................................................................................1834 PC360LC-10....................................................................................................................1834 PC390LC-10....................................................................................................................1835 Track Shoe........................................................................................................................1836 PC360LC-10....................................................................................................................1836 PC390LC-10....................................................................................................................1840 Triple Grouser Shoe...............................................................................................................1842 PC360LC-10....................................................................................................................1842 PC390LC-10....................................................................................................................1843 HYDRAULIC SYSTEM......................................................................................................................1844 Hydraulic Tank....................................................................................................................1844 Main Pump.........................................................................................................................1845 Control Valve.....................................................................................................................1846 General View..................................................................................................................1846 Sectional View (1/5)..........................................................................................................1848 Sectional View (2/5)..........................................................................................................1850 Sectional View (3/5)..........................................................................................................1852 Sectional View (4/5)..........................................................................................................1854 Sectional View (5/5)..........................................................................................................1856 Swing Motor.......................................................................................................................1858 Travel Motor......................................................................................................................1862 PPC Valve.........................................................................................................................1866 Work Equipment and Swing PPC Valve............................................................................................1866 Travel PPC Valve..............................................................................................................1869 1st-Line Attachment PPC Valve (with EPC Valve)................................................................................1872 EPC Valve.....................................................................................................................1874 2nd-Line Attachment PPC Valve.................................................................................................1876 Solenoid Valve....................................................................................................................1878 Attachment Circuit Selector Valve.................................................................................................1880 Center Swivel Joint...............................................................................................................1882 WORK EQUIPMENT........................................................................................................................1883 Dimensions of Components..........................................................................................................1883 Dimensions of Arm.................................................................................................................1888 Boom Cylinder.....................................................................................................................1896 Arm Cylinder......................................................................................................................1897 Bucket Cylinder...................................................................................................................1898 80 AIR CONDITIONER........................................................................................................................1899 AIR CONDITIONER.......................................................................................................................1901 Precautions for Refrigerant.......................................................................................................1901 Air Conditioner Component.........................................................................................................1902 Structure and Function of Refrigeration System....................................................................................1905 Overview of Refrigeration System..................................................................................................1906 Air Conditioner Unit..............................................................................................................1908 Function......................................................................................................................1909 Functions of Major Components.................................................................................................1910 Dual Pressure Switch..............................................................................................................1914 Air Conditioner Controller........................................................................................................1914 Air Conditioner Compressor........................................................................................................1915 Air Conditioner Condenser.........................................................................................................1916 Receiver Drier....................................................................................................................1917 Sunlight Sensor...................................................................................................................1918 Outside Air Temperature Sensor....................................................................................................1918 Procedure for Testing and Troubleshooting.........................................................................................1920 Basic Inspection and Troubleshooting Sequence.................................................................................1920 Air Conditioner Circuit Diagram and Arrangement of Connector Pins.................................................................1922 System Diagram....................................................................................................................1923 Air Conditioner Controller Input and Output Signals...............................................................................1924 Parts and Connectors Layout.......................................................................................................1926 Layout of Air Conditioner Related Parts and Connectors............................................................................1927 Testing Air Leakage (Duct)........................................................................................................1929 Testing with Self-Diagnosis Function..............................................................................................1932 How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...................................1933 Testing Vent (Mode) Changeover....................................................................................................1935 Testing FRESH/RECIRC Air Changeover...............................................................................................1937 Testing Sunlight Sensor...........................................................................................................1938 Testing (Dual) Pressure Switch for Refrigerant....................................................................................1939 Testing Relay.....................................................................................................................1940 Troubleshooting Chart 1...........................................................................................................1941 Troubleshooting Chart 2...........................................................................................................1942 Information Mentioned in Troubleshooting Table....................................................................................1945 Information in Troubleshooting Table..........................................................................................1945 Failure Code List Related to Air Conditioner......................................................................................1946 879AKA - A/C Inner Sensor Open Circuit............................................................................................1947 879AKB - A/C Inner Sensor Short Circuit...........................................................................................1947 879BKA - A/C Outer Sensor Open Circuit............................................................................................1948 879BKB - A/C Outer Sensor Short Circuit...........................................................................................1950 879CKA - Ventilating Sensor Open Circuit..........................................................................................1952 879CKB - Ventilating Sensor Short Circuit.........................................................................................1953 879DKZ - Sunlight Sensor Open or Short Circuit....................................................................................1954 879EMC - Ventilation Damper Abnormality...........................................................................................1956 879FMC - Air Mix Damper Abnormality...............................................................................................1957 879GKX - Refrigerant Abnormality..................................................................................................1958 A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)................................................1960 A-2 Troubleshooting of Compressor System (Air is Not Cooled)......................................................................1962 A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)..........................................1966 A-4 Troubleshooting for FRESH/RECIRC Air Changeover...............................................................................1968 Troubleshooting with Gauge Pressure...............................................................................................1970 [Measurement Condition for Pressure]..........................................................................................1970 Testing Refrigerant Pressure......................................................................................................1973 Check.........................................................................................................................1974 Precautions for Disconnecting and Connecting Refrigerant Piping...................................................................1976 Disconnection.................................................................................................................1976 Connection....................................................................................................................1976 Tightening Torque for Joint Portion of Refrigerant Piping.........................................................................1977 Handling of Compressor Oil........................................................................................................1978 Oil Level Control of Compressor...............................................................................................1978 Refilling of Compressor Oil...................................................................................................1978 90 DIAGRAMS AND SCHEMATICS................................................................................................................1981 HYDRAULIC SYSTEM......................................................................................................................1983 Hydraulic Circuit Symbols.........................................................................................................1983 Hydraulic Circuit Diagram.........................................................................................................1987 ELECTRICAL SYSTEM.....................................................................................................................1988 Electrical Symbols................................................................................................................1988 Air Conditioner Electrical Diagram................................................................................................1998 Electrical Circuit Diagram (1/6)..................................................................................................1992 Electrical Circuit Diagram (2/6)..................................................................................................1993 Electrical Circuit Diagram (3/6)..................................................................................................1994 Electrical Circuit Diagram (4/6)..................................................................................................1995 Electrical Circuit Diagram (5/6)..................................................................................................1996 Electrical Circuit Diagram (6/6)..................................................................................................1997
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